System and method for photocatalytic oxidation air filtration using a substrate with photocatalyst particles powder coated thereon

Abstract

The present invention relates to an air filtration system and a method for making a photocatalytic oxidation substrate by powder coating a photocatalyst onto a metal substrate.

1. A method for applying a photocatalyst onto a substrate useful in a photocatalytic oxidation air filtration system comprising the steps of:
 a. mixing a metal oxide photocatalyst with a polymeric resin to form a photocatalyst-resin mixture comprised of about 70% by weight of titanium dioxide and about 30% by weight of polymeric resin; 
 b. electrically charging the photocatalyst-resin mixture; 
 c. spraying the photocatalyst-resin mixture onto the substrate to form a photocatalyst powder-coated substrate; and 
 d. heating the photocatalyst powder-coated substrate. 
 
     
     
       2. The method of  claim 1 , wherein the photocatalytic oxidation air filtration system further comprises:
 a. a particulate filter; 
 b. a motor fan for propelling airflow; 
 c. the photocatalyst powder-coated substrate; and 
 d. a UV light source for irradiating UV light on the photocatalyst powder-coated substrate. 
 
     
     
       3. The method of  claim 2 , wherein the substrate is woven. 
     
     
       4. The method of  claim 1 , wherein the photocatalytic oxidation air filtration system further comprises:
 a. a particulate filter; 
 b. the photocatalyst powder-coated substrate; 
 c. at least one UV light source for irradiating UV light on the substrate; and 
 d. at least one reflector positioned adjacent the at least one UV light source for reflecting UV light toward the substrate. 
 
     
     
       5. The method of  claim 4 , wherein the particulate filter is a MERV 8 or higher pleated filter. 
     
     
       6. The method of  claim 1 , wherein the substrate has a structure selected from the group consisting of: a honeycomb, fins, a mesh, a fibrous structure, or a filamentous structure. 
     
     
       7. The method of  claim 1 , wherein the titanium dioxide is P25 titanium dioxide having an average particle size of about 134 μm on the substrate. 
     
     
       8. The method of  claim 1 , further comprising the step of heating the substrate for a time and at a temperature sufficient to cure the photocatalyst-resin mixture on the substrate. 
     
     
       9. The method of  claim 1 , wherein the substrate comprises aluminum. 
     
     
       10. The method of  claim 1 , wherein the polymer resin further comprises a terephthalate ester-based resin.